Elastic functional textile fabric and dyeing and finishing method thereof

ABSTRACT

This invention relates to an elastic functional textile fabric and dyeing and finishing method thereof. The fabric provided mainly comprises at least one elastic yarn. An ironing machine is used to process the fabric to maintain warp-wise smoothness and flatness. After ironing, a sanforizing machine is used to sanforize the fabric, and then the fabric undergoes a scutching procedure. Then, a setting machine is used to preset the scutched fabric, the fabric undergoes a dyeing procedure to form an elastic fabric. Then, the elastic fabric undergoes a second scutching procedure and a second setting procedure to form the finished product as the elastic functional textile fabric according to this invention. Through the production method disclosed above, problematic situations like insufficient weft weight, unsmooth fabric surface, pitting surface, uneven dyeing, side shading, poor fastness, chromatic aberration, dyelot chromatism, insufficient elasticity, as well as spray burns, etc can be dramatically reduced.

BACKGROUND OF INVENTION 1. Field of the Invention

The invention relates to an elastic fabric, in particular to a unique elastic functional textile fabric made of polyurethane elastic fiber, featuring highly uniform dyeing, high color fastness, low chromatic aberration, high flexibility, and high elastic recovery rate, produced through a special dyeing and finishing process, and the dyeing and finishing method thereof.

2. Description of Related Art

The textile industry has developed in Taiwan for more than 50 years. From pure cotton textiles in the early state to the subsequent chemical fiber textiles, the textile industry has been one of the key industries in Taiwan. After so many years of continuous industrial upgrading, Taiwan's textile entrepreneurs have an in-depth understanding of the newest trend and latest technology in the textile world. Thanks to persistent effort and expansion made by relevant manufacturers, the export volume of the textile industry has always been ranked among the top industries in Taiwan. In particular, dyeing and finishing is an important sector to be developed in the textile industry in Taiwan.

With the economic development and people's increasing awareness of and care about their own health, the sports industry is also flourishing, and the sales volume of functional sportswear is increasing dramatically. Comfortability, convenience and functional performance of the functional sportswear are often the key factors for consideration when consumers make purchasing decisions. In particular, when buying functional sportswear, consumers care most about elasticity, quick and effective moisture absorption and perspiration, antibacterial and anti-odor functions, as well as the light-to-wear property. Among them, the elasticity of the sportswear can be directly and easily felt and judged by general consumers with mere sensory touch. As a matter of fact, elastic textile fabric can reduce the sense of restraint and offer more flexibility for movement and more comfort in wearing. Therefore, elasticity is a critical factor to consider when a consumer makes a purchasing decision. In the current market, common materials for elastic functional textile fabrics include polyurethane elastic fibers, polyether ester elastic fibers, polyolefin elastic fibers, polytrimethylene terephthalate fibers, two-component composite crimped fibers, hard elastic fibers, etc. The most successful commercialized elastic fibers in the market are the polyurethane elastic fibers developed by the American company DuPont in 1959. In the United States and Canada, it is called Spandex or Lycra. In Taiwan, it is usually called OP. Because the polyurethane elastic fiber is composed of special hard and soft chain interlaced molecular structures, it features high ductility and high elastic recovery rate. Due to minimal interaction force between the molecular chains, it can be freely elongated, offering perfect stretching performance. Its rigid molecular chains offer strong binding forces and the molecular chains cannot be stretched indefinitely. Therefore, it offers an excellent fiber recovery rate. Apart from maximum stretch up to 600% and perfect recovery, it also features high strength as well as breathable and wear-resistant properties.

As mentioned above, polyurethane elastic fibers are playing a significant role in the textile industry. However, in the processes of dyeing, false twisting and weaving to make polyurethane elastic fibers into elastic functional textile fabrics, there are often such problematic situations as uneven dyeing, side shading, dyeing creases, poor fastness, poor elasticity, low elastic recovery rate, cloud spots, unsmooth surface, or chromatic aberration, or dyelot chromatism. As a result, when downstream manufacturers and consumers purchase elastic functional textile fabrics, they are always concerned about quality difference or poor performance. Therefore, it has become an important task for textile manufactures to find a solution for mass production of textile products featuring high elasticity, light weight, even dyeing, good elasticity, smooth fabric surface and touch, while at the same time reducing production cost so that downstream garment manufacturers or consumers will quickly accept and buy in large quantities. In view of this, fiber textile processors are currently seeking to develop a production method to manufacture elastic functional textile fabrics featuring high elasticity, high dyeing strength, light weight, good heat insulation, fast drying, comfortable wearing, as well as stain resistance to make the fabrics easy to wash.

SUMMARY OF THE INVENTION

In view of the current situation, the inventor has conducted numerous researches in the development of solutions to the technical problems mentioned above. Based on years of professional experience and deliberate survey and study, the inventor has successfully developed the present invention to improve the manufacturing processes for elastic textile fabrics, and solve the problems existing in the prior art.

The main object of the present invention is to provide improved production processes to greatly enhance the dyeing quality, smoothness and elasticity of functional elastic fibers and to produce elastic functional textile fabrics with optimal functional performance.

Another object of the invention is to solve the common problems of insufficient weft weight, water ripples, unsmooth surface, pitting surface, creases, uneven dyeing, side shading, poor fastness, chromatic aberration, dyelot chromatism, insufficient elastic force, and spray burns through special improved production processes, and to enhance the quality and performance of elastic fabrics.

A further object of the invention is to simplify the original complicated manufacturing procedures through special improved production processes. The fabrics are directly washed after high-temperature dyeing, and then the fabrics undergo a setting procedure, thus saving a lot of processing time and considerably reducing the manufacturing cost.

In order to achieve the above objects, the method disclosed in the invention comprises a medium and light color dyeing and finishing method and a dark color dyeing and finishing method, respectively comprising following steps:

Medium and Light Color Dyeing and Finishing Method: A fabric is provided. The fabric comprises at least one elastic yarn. A ironing machine is used to process the fabric. The fabric undergoes an ironing procedure at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness. After ironing, a sanforizing machine is used to sanforize the fabric. Then after loosening, the fabric undergoes a scutching procedure. Then, a setting machine is used to preset the scutched fabric at temperatures from 180° C. to 195° C. Then, a dyeing procedure is adopted to dye the fabric into a medium and light color elastic fabric. Then, the fabric undergoes a second scutching procedure and a finished product setting through a setting machine at temperatures from 150° C. to 170° C.

Dark Color Dyeing and Finishing Method: A fabric is provided. The fabric comprises at least one elastic yarn. A ironing machine is used to process the fabric. The fabric undergoes an ironing procedure at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness. After ironing, a sanforizing machine is used to sanforize the fabric. Then after loosening, the fabric undergoes a scutching procedure. Then, a setting machine is used to preset the scutched fabric at temperatures from 180° C. to 195° C. Then, a dyeing procedure is adopted to dye the fabric into a dark color elastic fabric. After dyeing, the dark color elastic fabric is put into a dye vat to undergo a washing procedure. Then, the fabric undergoes a second scutching procedure and a finished product setting through a setting machine at temperatures from 120° C. to 140° C.

In this way, through the dyeing and finishing method for elastic function textile fabrics disclosed in the present invention, problematic situations like insufficient weft weight, unsmooth fabric surface, pitting surface, uneven dyeing, side shading, poor fastness, chromatic aberration, dyelot chromatism, insufficient elasticity, as well as spray burns, etc can be dramatically reduced. The improvements are detailed as below:

-   -   (1) Solution to insufficient weft weight: Generally, when an         elastic fabric undergoes a ironing procedure, the polyester         fibers may often become firm due to excessive warp pulling,         over-speed, or over-temperature. The invention uses a machine to         loosen the fabric at 120° C. for 30 minutes after the fabric         going through the ironing machine. This can considerably reduce         the problematic situations of insufficient weft weight.     -   (2) Solution to unsmooth fabric surface and pitting surface:         Situations like unsmooth fabric surface and pitting surface may         often occur due to insufficient ironing temperature or         over-speed when the elastic fabric undergoes an ironing         procedure during the dyeing and finishing process. The invention         reduces the ironing speed to 25 m/min to set the fabric, and         thus can considerably reduce the problematic situations of         unsmooth fabric surface and pitting surface.     -   (3) Solution to uneven dyeing and side shading: When dyeing         elastic fabrics, uneven dyeing and side shading are usually         caused by such factors as dyeing heating curve, temperature         holding time, dosage of medicament, etc. By adjusting the         heating speed of the dyeing machine, the dyeing evenness of the         elastic fabrics can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of the elastic functional textile fabric according to the invention.

FIG. 2 is a flow chart of the dyeing and finishing method for medium and light color elastic fabrics according to the invention.

FIG. 3 is a flow chart of the dyeing and finishing method for dark color elastic fabrics according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

For better understanding of the objects, the technical solutions, and the advantages of the present invention, detailed descriptions are provided below with respect to a preferred embodiment. While a preferred embodiment of the present invention has been described in detail, it is to be understood that various equivalents, modifications, alterations or changes may be made by those skilled in the art without departing from the spirit of the present invention and shall be covered by the scope of the invention.

The invention discloses an “elastic functional textile fabric”. Referring to FIG. 1 and FIG. 2, a schematic diagram of the elastic functional textile fabric and a flow chart of the dyeing and finishing method for medium and light color elastic fabric are depicted. The method disclosed in the invention includes the following steps:

-   -   S1: A fabric (1) is provided. The fabric (1) is in a sheet         structure, comprising at least one elastic yarn (11).         Specifically, an ironing machine is used to process the fabric         (1). The fabric (1) undergoes an ironing procedure at a speed of         25 m/min, and at temperatures from room temperature to 110° C.,         130° C. and 150° C., to maintain warp-wise smoothness and         flatness.     -   S2: A sanforizing machine is used to sanforize the fabric (1) at         temperatures from 90° C. to 97° C., to adjust the tension         according to the condition of the fabric surface.     -   S3: The fabric (1) is loosened at 120° C. for 30 minutes, and         then undergoes a scutching procedure.     -   S4: A setting machine is used to preset the fabric (1) at         temperatures from 180° C. to 195° C.     -   S5: A dyeing procedure is adopted to dye the fabric (1) into a         medium and light color elastic fabric.     -   S6: A second scutching procedure is conducted, and then, a         setting machine is used to conduct finished product setting at         temperatures from 150° C. to 170° C. By now, a functional         elastic fabric with stable quality can be formed, considerably         reducing the problematic situations like insufficient weft         weight, unsmooth fabric surface, pitting surface, uneven dyeing,         side shading, etc.

Refer to FIG. 3, a flow chart of the dyeing and finishing method for dark color elastic fabric of the invention is provided. The method includes the following steps:

-   -   S7: A fabric (1) is provided. The fabric (1) is in a sheet         structure, comprising at least one elastic yarn (11).         Specifically, an ironing machine is used to process the fabric         (1). The fabric (1) undergoes an ironing procedure at a speed of         25 m/min, and at temperatures from room temperature to 110° C.,         130° C. and 150° C., to maintain warp-wise smoothness and         flatness.     -   S8: A sanforizing machine is used to sanforize the fabric (1) at         temperatures from 90° C. to 97° C., to adjust the tension         according to the condition of the fabric surface.     -   S9: The fabric (1) is loosened at 120° C. for 30 minutes, and         then undergoes a scutching procedure.     -   S10: A setting machine is used to preset the fabric (1) at         temperatures from 180° C. to 195° C.     -   S11: A dyeing procedure is adopted to dye the fabric (1) into a         dark color elastic fabric.     -   S12: The dark color elastic fabric is put into a dye vat to         undergo a washing procedure. After that, a second scutching         procedure is conducted, and then, a setting machine is used to         conduct finished product setting at temperatures from 120° C. to         140° C. By now, a functional elastic fabric with stable quality         can be formed, considerably reducing the problematic situations         like insufficient weft weight, unsmooth fabric surface, pitting         surface, uneven dyeing, side shading, etc.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

To sum up, the embodiment of the invention can truly achieve the desired effect. The specific structure of the disclosure has not been found in similar products, nor has it been disclosed before the application of the present invention. Therefore, it meets the relevant provisions and requirements set forth in the Patent Law. Accordingly, an application for patent is submitted herein. Your auditing and approval will be highly appreciated. 

1. An elastic functional textile fabric, comprising: a fabric, said fabric being in a sheet structure, comprising at least one elastic yarn, specifically, an ironing machine is used to process the fabric, the fabric undergoes an ironing procedure at a speed of 25 m/min, and at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness, then, a sanforizing machine is used to sanforize the fabric at temperatures from 90° C. to 97° C., to adjust the tension according to the condition of the fabric surface, the fabric is then loosened at 120° C. for 30 minutes, and then undergoes a scutching procedure, a setting machine is used to preset the scutched fabric at temperatures from 180° C. to 195° C., then, a dyeing procedure is adopted to dye the fabric into a medium and light color elastic fabric, after that, a second scutching procedure is conducted, and then, a setting machine is used to conduct finished product setting at temperatures from 150° C. to 170° C.
 2. An elastic functional textile fabric, comprising: a fabric, said fabric being in a sheet structure, comprising at least one elastic yarn, specifically, an ironing machine is used to process the fabric, the fabric undergoes an ironing procedure at a speed of 25 m/min, and at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness, then, a sanforizing machine is used to sanforize the fabric at temperatures from 90° C. to 97° C., to adjust the tension according to the condition of the fabric surface, the fabric is then loosened at 120° C. for 30 minutes, and then undergoes a scutching procedure, a setting machine is used to preset the scutched fabric at temperatures from 180° C. to 195° C., then, a dyeing procedure is adopted to dye the fabric into a dark color elastic fabric, the dark color elastic fabric is put into a dye vat to undergo a washing procedure, after that, a second scutching procedure is conducted, and then, a setting machine is used to conduct finished product setting at temperatures from 120° C. to 140° C.
 3. A dyeing and finishing method for elastic functional textile fabrics, comprising the following steps: S1: a fabric is provided, the fabric is in a sheet structure, comprising at least one elastic yarn, specifically, an ironing machine is used to process the fabric, the fabric undergoes an ironing procedure at a speed of 25 m/min, and at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness, S2: a sanforizing machine is used to sanforize the fabric at temperatures from 90° C. to 97° C., to adjust the tension according to the condition of the fabric surface, S3: the fabric is loosened at 120° C. for 30 minutes, and then undergoes a scutching procedure, S4: a setting machine is used to preset the fabric at temperatures from 180° C. to 195° C., S5: a dyeing procedure is adopted to dye the fabric into a medium and light color elastic fabric, S6: a second scutching procedure is conducted, and then, a setting machine is used to conduct finished product setting at temperatures from 150° C. to 170° C.,
 4. A dyeing and finishing method for elastic functional textile fabrics, comprising the following steps: S7: a fabric is provided, the fabric is in a sheet structure, comprising at least one elastic yarn, specifically, an ironing machine is used to process the fabric, the fabric undergoes an ironing procedure at a speed of 25 m/min, and at temperatures from room temperature to 110° C., 130° C. and 150° C., to maintain warp-wise smoothness and flatness, S8: a sanforizing machine is used to sanforize the fabric at temperatures from 90° C. to 97° C., to adjust the tension according to the condition of the fabric surface, S9: the fabric is loosened at 120° C. for 30 minutes, and then undergoes a scutching procedure, S10: a setting machine is used to preset the fabric at temperatures from 180° C. to 195° C., S11: a dyeing procedure is adopted to dye the fabric into a dark color elastic fabric, S12: the dark color elastic fabric is put into a dye vat to undergo a washing procedure, after that, a second scutching procedure is conducted, and then, a setting machine is used to conduct finished product setting at temperatures from 120° C. to 140° C.
 5. The elastic functional textile fabric defined in claim 1, wherein, said dyeing procedure includes a dyeing procedure containing small particle dyes, and the dyeing machine conducts dyeing at an initial heating speed of 0.8° C./min, when the overall temperature reaches 110° C., the dyeing is conducted at a heating speed of 1.5° C./min.
 6. The elastic functional textile fabric defined in claim 2, wherein said dyeing procedure includes a dyeing procedure containing small particle dyes, and the dyeing machine conducts dyeing at an initial heating speed of 0.8° C./min, when the overall temperature reaches 110° C., the dyeing is conducted at a heating speed of 1.5° C./min.
 7. The elastic functional textile fabric defined in claim 1, wherein the dyeing procedure includes a dyeing procedure containing large particle dyes, and the dyeing machine conducts continuous dyeing at a heating speed of 1° C./min.
 8. The elastic functional textile fabric defined in claim 2, wherein the dyeing procedure includes a dyeing procedure containing large particle dyes, and the dyeing machine conducts continuous dyeing at a heating speed of 1° C./min.
 9. The elastic functional textile fabric defined in claim 1, wherein said washing procedure uses sodium hydrate and thiourea dioxide, wherein first-time washing is conducted at 80° C. for 5 minutes, and after drainage, second-time washing is conducted at 80° C. for 5 minutes, and then glacial acetic acid and water are added to for neutralization.
 10. The elastic functional textile fabric defined in claim 2, wherein said washing procedure uses sodium hydrate and thiourea dioxide, wherein first-time washing is conducted at 80° C. for 5 minutes, and after drainage, second-time washing is conducted at 80° C. for 5 minutes, and then glacial acetic acid and water are added to for neutralization. 